Epoxy resin compositions

ABSTRACT

Novel epoxy resin compositions of epoxy resin and 1,3,6triaminomethyl hexane or the adduct thereof with, if needed, active alumina and/or silica alumina are provided. The composition, useful for paint and adhesive agents, instantly shows superior adhesive, chemical and electrical properties even under water and at a temperature below 5*C.

United States Patent Komoto et al.

[ Dec. 30, 1975 EPOXY RESIN COMPOSITIONS Inventors: Hiroshi Komoto, Tsurugashima; Kaoru Ohmura, Asaka, both of Japan Asahi Kasei Kogyo Kabushiki Kaisha, Osaka, Japan Filed: May 24, 1973 Appl. No.: 363,674

Published under the Trial Voluntary Protest Program on January 28, 1975 as document no. B 363,674.

Assignee:

Foreign Application Priority Data June 5, 1972 Japan 47-55141 US. Cl 260/37 EP; 260/47 EN Int. Cl. C08L 63/02 Field of Search 260/37 EP, 47 EN [56] References Cited UNITED STATES PATENTS 3,297,608 l/l967 Noshay et al 260/47 EN X 3,464,854 9/1969 Bolger 260/37 EP X Primary Examiner-Allan Lieberman Assistant Examiner-E. Suzanne Parr Attorney, Agent, or Firm-Burgess, Dinklage & Sprung [57] ABSTRACT Novel epoxy resin compositions of epoxy resin and and at a temperature below 5C.

' 1 5 Claims, N0 Drawings I1 EPOXY RESIN COMPOSITIONS BACKGROUND OF THE INVENTION Epoxy resin has been widely used for paints, adhesive agents, etc., due to its superior chemical resistance, adhesive properties and electrical properties. However, there is practically no epoxy resinwhich i s.curable under water. Therefore, for the use under water of epoxy resin, epoxy resin has been covered by film. However, even by employing this convenient method, no conventionally known epoxy resin could give satisfactory results. r i

On the other hand, as the ocean industry grows year by year, the development of epoxy resin curable under water is strongly demanded.

In addition, there has been practically no epoxy resin, which is curable below 5C and possesses satisfactory physical properties. For example, US. Pat. No.

3,639,344 was proposed for thispurpose, but the composition according to this US. Patent gave only insufficient and unsatisfactory strength SUMMARY OF THE INVENTION The present invention relates to an epoxy resin composition comprising:

1. I00 parts by weight of epoxy resin; and

II. I 200 parts by weight of 1,3,6-triaminomethyl hexane or the reaction product thereof with an adduct forming compound.

The epoxy resin composition according to the present invention can be further combined, in addition to the said amount of ingredients (I) and (II), with (III) 5 200 parts by weight of one, or a mixture, of active alumina and silica alumina. 0

DETAILED DESCRIPTION OF THE INVENTION polyhydric alcohol such as glycol, glycerine and trimethylol propane; polyhydric phenol such as resorcinol, hydroquino'ne, cate'chol and phloroglycinol; and polyphenol such as 2,2-bis-(4-hydroxyphenyl)-pro pane, p,p'-dihydroxydiphenyl, bis-(4-hydroxyphenyl) sulfone, 2,2'-dihydroxyl,l'-dinaphthylmethane and novolak resin; with an excess of epoxide such as alkylene oxide and epihalohydrin.

Particularly preferable examples are: epoxy resin repesented by the general formula mzf'f z on f (1 y f-O-O (:32 ca\ 082 wherein n represents mean value of 0 10 preferably 0 or novolak epoxy resinwhich is a reaction product of novolak'resin and epichlorohydrin and which is represented by the general formula of wherein m represents mean value of 0-- about 5. Gen erally, any epoxy resin which is liquid with a melting point not more than 20Cis suitable. However, powdery epoxy resin can also be employed for the invention, preferably in such case with the use of solvent such as toluene, methylethylketone and cellosolve. Further, epoxy resin dispersed in water can also be used.

Compounds suitably used for the ingredient (II) according to the invention are 1,3,6-triaminomethyl hexane-and a reaction product of 1,3,6-triaminomethyl hexane with an adduct forming compound,for example monoepoxide such as ethylene oxide, propylene oxide, octylene oxide, styrene oxide, a-pinene oxide, cyclohexane vinyl mono-oxide and glycidyl ester; di-epoxide such .as butadiene dioxide, di-glycidyl ether, limonene dioxide, divinyl benzene dioxide, vinyl cyclohexane dioxide, bis(2,3-epoxy cyclopentyl) ether and 2-glycidyl phenylglycidyl ether; epoxy resins as represented by the said generalformula (1) and (2), preferably epoxy resins having a softening point not more than 20C; and vinyl compounds such as acrylonitrile, methyl methacrylate and vinyl chloride. r a g The amount, based on I mol of 1,3,6-triaminomethyl hexane, of diepoxide or epoxy resin is not more than 0.5 mol; and the amount based .onl mol of 1,3,6- triaminomethylhexane of mono-epoxide or vinyl compound is l 4 mol. 7

l,3,6 Triaminomethylhexane used in the invention can be easily obtained by hydrogenating under pressure and in,the,presence of hydrogenation catalyst such as Raney nickel 1,3,6-tricyano hexane obtained byelectroreductive reaction of acrylonitrile. Adducts from l,3,6-triaminomethyl hexane and adduct forming compounds, for example, acrylonitrile can be easily obtained by the reaction at an elevated temperature.

The amount of (II) is l 200 parts based on 100 parts of epoxy resin, preferably 10 parts more preferably 20-70 parts. With less than 1 part, the curing speed is too slow. With more than 200 parts, workability becomes insufficient. I

Parts means parts by weight in the present specification.

For the ingredient (III) according to the present in-.

vention, active alumina and silica alumina are suitable. Preferably, these compounds should be dry and possess not more than 40 of absorbed water. In case the compound has more than 40 of absorbed water, the adhesive strength in water or on wet substrate is decreased, and in case a dry compound is employed, no such troublesome decrease of adhesive strength is observed. As to the particle size of the ingredient (Ill),

smaller particles with larger surface, preferably not larger than 50 mesh and having a bulk density not more ,than 1.0 is suitable. For the use in water, it is preferable to employ y-A1 O or 'y-Al O H O with a bulk density not more than 0.5. For active alumina, A1 A1 0 H 0, and A1 0 31-1 0, especially 'y-Al O 'y-Al O H 0, and 'y-Al O '3H O are suitable. The addition of these compounds surprisingly promotes curing on the surface of the substrate under water and formation of a smooth coat on the surface of the substrate under water.

The amount of ingredient (111) is 5 200 parts, preferably l0 150 parts.

If needed in the present invention in addition to the above mentioned ingredients (1), (11) and (iii), any of known fillers, reinforcing agents, additives and pigments can be employed.

Examples of fillers, reinforcing agents, additives and pigments are: coal tar, glass fiber, asbestos fiber, boron fiber, carbon fiber, cellulose, polyethylene powder, polypropylene powder, quartz powder, mineral silicatessuch as mica, asbestos powder, slate powder, kaolin, aluminum hydroxide, chalk powder, gypsum, calcium carbonate, antimony trioxide, bentonite, silica aerosol, lifton, barite, titanium dioxide, carbon black, graphite, and oxide compound pigments such as iron oxide or metallic powder for example aluminum powder or iron powder.

Further, any known curing agents can also be used. These include aliphatic polyamines for example diethylene triamine, triethylene tetramine, diethylamino propyl amine, hexamethylene diamine tris (dimethylaminomethyl) phenol, xylene diamine, etc.; aromatic polyamines for example metaphenylene diamine, diamino diphenyl methane, diamino diphenyl sulfone, etc.; polycarboxylic acid and anhydride thereof for example plithalic anhydride, trimellitic anhydride, pyromellitic anhydride etc.; polycarboxylic acid hydrazide; dicyano diamide, and BF -amine complex compounds.

The composition obtained according to the present invention shows superior adhesive ability on wet substrate-or under water at lower temperature e.g. from 5C toC. Further, to meet the specific objectives, curing promoting agents such as phenols for example m-cresol, phenol, salicylic acid, or triphenyl phosphite, etc. can be added.

The present invention will be further illustrated by, but not limited to, the following examples.

1n the Examples, parts means parts by weight, Charpy impact strength and shear adhesive strength'are measured by .11SK-69l l and ASTMD1002-64, respectively.

EXAMPLE 1 EXAMPLE 2 27.0parts of epoxy resin (bisphenol A type: epoxy equivalent 184 194) sold under the trademark Epikote" 828 by Shell Chemical Co., 1 1.5 parts of epoxy resin (polyglycol type: epoxy equivalent 305 335) sold under trademark ofDER-732 by Dow Chemical Co., 31.2 parts of titanium dioxide, 0.14 part of polyoxyethylene alkyl phenol ether type emulsifier (sold under trademark Neugen EA 137 by Daiichi Kogyo Seiyaku Co.), 0.14 parts of polyoxyethylene polyoxypropylene condensate type emulsifier (sold under trademark of EPAN-785 by Daiichi Kogyo Seiyaku Co.), 0.14 part of polyoxyethylene no nyl phenol ether type emulsifier (sold under trademark of Neugen BA 50 by Daiichi Kogyo Seiyaku Co.) and 0.5 part by weight of defoaming agent (which is'sold under trademark of Silicone KM 73 by Shinetsu Chemical Co.) were blended by a kneader and then titanium dioxide was thoroughly dispersed by a rolling mill to obtain a pigment paste.

To 70.89 parts of thus obtained pigment paste heated at 50C, 29.1 1 parts of water heated at 50C was added while being throughly stirred by a high speed mixer (or homogenizor) to obtain an emulsion type epoxy resin containing titanium dioxide.

Into thus obtained parts of oil-in-water type epoxy resin dispersion, 5 parts of 1,3,6-triaminomethyl hexane was blended. Compatibility at the time of blending was favorable. Then, the thus obtained mixture was coated on a tin plate sheet by using a 10 mmdoctor blade and the laminate thus formed was satisfactory. The sample was left to stand for 7 days at room temperature. Testing for curing by JlS-K-5400 indicated perfect curing was obtained. Further, the sample after J lS-K-5400 testing was immersed in water at room temperature for 30 days to test water proof properties which were also favorable.

EXAMPLE 3 100 Parts of epoxy resin (bisphenol A type containing 20 weight of butyl glycidyl ether: epoxy equivalent sold under trademark DER-335.1" by Dow Chemical Co. and 17 parts of 1,3,6- triaminomethyl hexane were mixed, adhered at 0C on a stainless steel sheet with a size of 3 X 3 cm and then left to stand for 1 week. Tensile adhesive strength was 1 10 kg/cm.

EXAMPLE 4 100 Parts of epoxy resin DER-331.1 as represented in Example 1, 7.5 parts of 1,3,6-triaminomethyl hexane, 10 parts of N-ethyl hexamethylene diamine and 50 parts of active alumina with a bulk density of 0.20 mainly consisting of -A|,o, H 0 were mixed and coated on steel sheet under water at 20C, and left to stand for 5.5 hours to obtain completely hardened laminate. The properties of thus obtained laminate were as follows.

Charpy impact strfigtl'tI l7gglftglcml rim) h dhesve stren t g cm i le filrzl stre ngth 180, pass (thickness of laminate: 65 Charpy impact strength 5 (kg cm/cm') 4 2mm) 50 p.) Shear adhesive strength 170 (kg/cm) EXAMPLE 5 7 (kg cmlcm Charpy impact strength 200 (kglcm Shear adhesive strength EXAMPLE 6 100 Parts of epoxy resin DER-331] as represented in Example 1, parts of 1,3,6-triaminomethyl hexane, 50 parts of anhydrous calcium sulphate and 30 parts of consisting of 'y-Al O 311 0 were mixed, coated under water at C on steel sheet and left to stand for 6 hours to obtain complete curing. The properties of the laminate were as follows.

Charpy impact strength 3 (kg cm/ m Shear adhesive strength 150 (kg/cm) EXAMPLE 9 Charpy impact strength 7 (kg cm/cm) Sh dh' t th 220 k 2 silica alumina with a bulk density of 0.35 were mixed ear a fame S reng g/cm and coated as in Example 4. After 6 hours, complete curing was achieved. The properties of the obtained laminate were as follows. CONTROL 1 Known typical curing agents were treated as in Ex- Charpy impact Strength 6 (kg cm-lcmz) ample to show comparison of curing times as de Shear adhesive strength 180 (kglcm fl m T l 1- Active alumina Charpy Shear epoxy resin Curing Agent (y-M 03) water curing impact adhesive (bulk density time strength strength 0.30),, kg cm/cm kg/cm "DER-331.1" Tris(dimethyl- 50 parts 20 parts 2 days 6 I 100 parts aminoethyl) phenol 20 parts DER-331]" acetyl 50 parts 20 parts 1 day 5 100 100 parts imidazole 10 parts EXAMPLE 10 60 Parts of e ox resin DER-331] as re resented in EXAMPLE 7 p y p parts of 1,3,6-triaminomethyl hexane and 37.8 parts of epoxy resin DER-331.! as represented in Example 1, 100 parts of active aluminav with a bulk density of 0.46 and mainly consisting of 'y-Al O H 0 and 2 parts of xylene-methyl isobutyl ketone-cellosolve (1:111) were mixed and coated as in Example 4. After 6 hours, com- Example 1, 40 parts of epoxy resin (bisphenol A type: epoxy equivalent "475 575) by Dow Chemical Co. sold under trademark of DER-66H, 10 parts of 1,3,6-triaminomethyl hexane, parts of active alumina with the bulk density of 0.46 and mainly consisting of 'y-Al O 20 parts of glass fiber powder and 2 parts of xylene-methylisobutyl ketone-cellosolve (1:1:1) were mixed and coated as in Example 4. After 3 hours, completecuring was attained to obtain smooth laminate. The properties of thus obtained laminate plete curing was attained to obtain smooth laminate.

The properties of the laminate were as follows. were as follows.

Charpy impact strength 7 (kg cm/cm) Charpy impact strength 8 (kg cm/cm) Shear adhesive strength 200 (kg/cm) Shear adhesive strength 180 (kg/cm) EXAMPLE 8 50 Parts of epoxy resin DER-331.! as represented in Example 1, 50 parts of coal tar, 17.3 parts of adduct obtained from 17.3 parts of 1,3,6-triaminomethyl hexane and 8.8 parts of ethylene oxide and 50 parts of active alumina with a bulk density of 0.40 and mainly EXAMPLE 1 l Charpy impact strength 7 (kg cm/cm) Shear adhesive strength 190 (kg/cm) I EXAMPLE 12 15 Parts of 1,3,6-triaminomethyl hexane, 100 parts of epoxy resin DER-3311 as represented in Example 1 and 100 parts of active alumina with the bulk density of 0.40 and mainly consisting of y-Al O were mixed, coated on a concrete sheet (30 X 30 X 6 cm) left to stand under water for 1 day; iron plate welded with nut at the center of the plate X 5 X 0.4 cm) was bonded thereto and then covered with wet cloth, and left to stand at room temperature. Tensile adhesive strength after 4 day was above 13 kg/cm and the material breaking occurred.

EXAMPLE 13 The same procedure as in Example 12 was followed, using 100 parts of epoxy resin DER-331J as represented in Example 1, 36.9 parts of adduct obtained from 34.6 parts of 1,3,6-triaminomethyl hexane and 21.6 parts of acrylonitrile, and 120 parts of active alunina with the bulk density of 0.85 and mainly consist- .ng of 'y-Al O Tensile adhesive strength after 1 day was above 12 kg/cm and the material breaking oc- :urred.

EXAMPLE 14 The same procedure as in Example 12 was followed, ising 100 parts of epoxy resin DER-331.1 as repreiented in Example 1, 31 parts of adduct obtained from 54.6 parts of 1,3,6-triaminomethyl hexane and 24 parts Jf styrene oxide, and 20 parts of active alumina with :he bulk density of 0.09 and mainly consisting of y- AI O H O. Tensile adhesive strength after 1 day was tbove 15 kg/cm and the material breaking occurred.

EXAMPLE 15 The same procedure as in Example 12 was followed, lsing mixture of 100 parts of epoxy resin DER-331.1 as 'epresented in Example 1, and powder curing agent of 25.2 parts of adduct obtained from 34.6 parts of 1,3,6- :riaminomethyl hexane and 13 parts of di-glycidyl :ther, which adduct was being adhered to 100 parts of tctive alumina with the bulk density of 0.40 and mainly :onsisting of 'y-Al O Tensile adhesive strength after I lay was above 13 kg/cm and the material breaking )ccurred.

EXAMPLE 16- 100 Parts of epoxy resin DER-331] as represented in Example 1, 42.7 parts of adduct obtained from 34.6 mm of 1,3,6-triaminomethyl hexane and 46 parts of glycidyl ester of 2,2-dimethyl octanoic acid, and 30 )arts of active alumina with the bulk densityof 0.10 md mainly consisting of -y-AI O H O were mixed; :oated on a concrete sheet (30 X 30 X6 cm) left to .t'and under water for 1 day; iron plate welded with nut it the center of the plate (5 X 5 X 0.4 cm) was bonded hereto; and allowed to stand under water at 25C.

Tensile adhesive strength after 1 day was above 11.5 kg/cm and the material breaking occurred.

EXAMPLE 17 Parts of epoxy resin DER-331.1 as represented in Example ,l,- 152 parts of adduct obtained from 34.6 parts of 1,3,6-triaminomethyl hexane and 138 parts of glycidyl ester of 2,2-dimethyl octanoic acid, 100 parts of coal tar and 10 parts of m-cresol were mixed and left to stand at room temperature. Curing was completed in 30 minutes and flexible cured product having hardness of 60 (by JIS A) was obtained.

EXAMPLE 18 The same procedure as in Example 1 was followed, using 100 parts of epoxy resin DER-33H as represented in Example 1 and 38.2 parts of adduct obtained from 34.6 parts of 1,3,6-t'riaminomethyl hexane and 23.2 parts of propylene oxide. Curing was completed in 3 hours. The properties of thus obtained laminate was as follows.

6 (kg cm/cm) (kg/cm) pass (thickness of laminate;

Charpy impact strength Shear adhesive strength Flexural strength EXAMPLE 19 The same procedure was followed as in Example 1, using 100 parts of epoxy resin DER-661] (bisphenol A type; epoxy equivalent 474 575) by Dow Chemical Co., 50 parts of xylene-methyl isobutyl ketone-cellosolve (121:1) and 12 parts of adduct obtained from 34.6 parts of 1,3,6-triaminomethyl hexane and 8.6 parts of acrylonitrile. Curing was completed in 3.5 hours. The properties of the resulting laminate were as follows.

7 (kg cm/cm) 180 (kglcm pass (thickness of laminate:

Charpy impact strength Shear adhesive strength Flexural strength 180,

EXAMPLE 20 7 (kg cm/cm) 200 (kg/cm) pass (thickness of laminate:

Charpy impact strength Shear adhesive strength Flexural strength 180",

d 2mm) What is claimed is:

1. An epoxy resin composition comprising: .1. 100parts by weight of an epoxy resin having at least two epoxy groups in the molecule; and

ll. 1-200 parts by weight of 1,3,6-triaminomethyl hexane or the reaction product thereof with an adduct forming compound selected from the group consisting of a. a diepoxide or a glycidyl epoxy resin in up to about 0.5 times the molar amount of the triaminomethyl hexane, and

b. a monoepoxide or a vinyl compound in about 1 to 4 times the molar amount of the triaminomethyl hexane.

2. An epoxy resin composition according to claim 1, further comprising:

lll. 5-200 parts by weight of one of active alumina, silica alumina or a mixture of active alumina and silica alumina.

3. The epoxy resin composition according to claim 1, wherein the amount of (l) is 100 parts and the amount of (II) is 70 parts.

4. The epoxy resin composition according to claim 1, wherein (ll) is the reaction product with the adduct forming compound of a diepoxide or glycidyl epoxy resin.

5. The epoxy resin composition according to claim 1, wherein (ll) is the reaction product with the adduct forming compound of a mono-epoxide or vinyl compound.

6. The epoxy resin composition according to claim 1, wherein the epoxy resin (1) is a glycidyl ether resin of at least one compound selected from the group consisting of bisphenol A, biscresol A and novolak.

7. The epoxy resin composition according to claim 2, wherein the amount of (l) is 100 parts, and amount of 10 (ll) is 10 parts and the amount of (III) is 10 parts.

8. The epoxy resin composition according to claim 2, wherein active alumina is one compound selected from the group consisting of y-Al O y-Al O H 0 and y- Al O -3H O and the mixture thereof.

9. The epoxy resin composition according to claim 2, wherein the bulk density of active alumina or silica alumina is not more that 1.0.

10. The epoxy resin composition according to claim 2, wherein (II) is the reaction product with an adduct forming compound selected from the group consisting of a diepoxide or a glycidyl epoxy resin.

11. The epoxy resin composition according to claim 2, wherein (II) is the reaction product with a adduct forming compound selected from the group consisting of a mono-epoxide or a vinyl compound.

12. The epoxy resin composition according to claim 2, wherein the epoxy resin (1) is a glycidyl ether resin of at least one compound selected from the group consisting of bisphenol A, biscresol A and novolak.

13. The epoxy resin composition according to claim 2, wherein active alumina is one compound selected from the group consisting of 'y-Al O or 'y-Al o H 0.

14. The epoxy resin composition according to claim 2, wherein the bulk density of active alumina or silica alumina is not more than 0.5.

15. The epoxy resin composition according to claim 1, wherein (ll) is the reaction product with a vinyl adduct forming compound selected from the group consisting of a nitrile, an acrylate or a halide. 

1. AN EPOXY RESIN COMPOSITION COMPRISING:
 1. 100 PARTS BY WEIGHT OF AN EPOXY RESIN HAVING AT LEAST TWO EPOXY GROUPS IN THE MOLECULE; AND II. 1-200 PARTS BY WEIGHT OF 1,3,6-TRIAMINOMTHYL HEXANE OR THE REACTION PRODUCT THEREOF WITH AN ADDUCT FORMING COMPOUND SELECTED FROM THE GROUP CONSISTING OF A. A DIEPOXIDE OF A GLYCIDYL EPOXY RESIN IN UP TO ABUT 0.5 TIMES THE MOLAR AMOUNT OF THE TRIAMINOMETHYL HEXANE AND B. A MONOEPOXIDE OR A VINYL COMPOUND IN A BOUT 1 TO 4 TIMES THE MOLAR AMOUNT OF THE TRIAMINOMETHYL HEXANE.
 2. An epoxy resin composition according to claim 1, further comprising: III. 5-200 parts by weight of one of active alumina, silica alumina or a mixture of active alumina and silica alumina.
 3. The epoxy resin composition according to claim 1, wherein the amount of (I) is 100 parts and the amount of (II) is 20 - 70 parts.
 4. The epoxy resin composition according to claim 1, wherein (II) is the reaction product with the adduct forming compound of a diepoxide or glycidyl epoxy resin.
 5. The epoxy resin composition according to claim 1, wherein (II) is the reaction product with the adduct forming compound of a mono-epoxide or vinyl compound.
 6. The epoxy resin composition according to claim 1, wherein the epoxy resin (I) is a glycidyl ether resin of at least one compound selected from the group consisting of bisphenol A, biscresol A and novolak.
 7. The epoxy resin composition according to claim 2, wherein the amount of (I) is 100 parts, and amount of (II) is 10 - 70 parts and the amount of (III) is 10 - 150 parts.
 8. The epoxy resin composition according to claim 2, wherein active alumina is one compound selected from the group consisting of gamma -Al2O3, gamma -Al2O3 .H2O and gamma -Al2O3 .3H2O and the mixture thereof.
 9. The epoxy resin composition according to claim 2, wherein the bulk density of active alumina or silica alumina is not more that 1.0.
 10. The epoxy resin composition according to claim 2, wherein (II) is the reaction product with an adduct forming compound selected from the group consisting of a diepoxide or a glycidyl epoxy resin.
 11. The epoxy resin composition according to claim 2, wherein (II) is the reaction product with a adduct forming compound selected from the group consisting of a mono-epoxide or a vinyl compound.
 12. The epoxy resin composition according to claim 2, wherein the epoxy resin (I) is a glycidyl ether resin of at least one compound selected from the group consisting of bisphenol A, biscresol A and novolak.
 13. The epoxy resin composition according to claim 2, wherein active alumina is one compound selected from the group consisting of gamma -Al2O3 or gamma -Al2O3 .H2O.
 14. The epoxy resin composition according to claim 2, wherein the bulk density of active alumina or silica alumina is not more than 0.5.
 15. The epoxy resin composition according to claim 1, wherein (II) is the reaction product with a vinyl adduct forming compound selected from the group consisting of a nitrile, an acrylate or a halide. 